Embroidering and dyeing system

TECHNICAL FIELD

The present invention relates to an embroidering and dyeing system. More particularly, the present invention pertains to an embroidering and dyeing system for embroidering on a work piece either before or after dyeing.

BACKGROUND ART

Embroidering and dyeing systems for embroidering on a work piece (e.g., garment) has been needed in an apparel manufacturer. A known embroidering and dyeing system described in Japanese Patent Laid-Open Publication No. H05-272046 includes an embroidering machine including a dyeing device.

With the construction of the known embroidering and dyeing system described in Japanese Patent Laid-Open Publication No. H05-272046, the dyeing device and the embroidering device are integrated as one unit.

Notwithstanding, the dyeing system cannot be operated during the operation of the embroidering machine, and the embroidering machine cannot be operated during the operation of the dyeing system. This yields the idle time, which declines the operational efficiency.

Further, with the construction of the known embroidering and dyeing system described in Japanese Patent Laid-Open Publication No. H05-272046, in case a predetermined pattern is dyed at the cloth after embroidering a predetermined pattern thereon, the cloth likely to shrink to displace the relative position of the embroidering pattern and the dyeing pattern, which decreases the quality of the patterns.

Still further, with the construction of the known embroidering and dyeing system described in Japanese Patent Laid-Open Publication No. H05-272046, embroidering and dyeing cannot be performed in case a particular color of the thread is finished and the there is no stock.

In addition, with the construction of the known embroidering and dyeing system described in Japanese Patent Laid-Open Publication No. H05-272046, because the embroidering and dyeing is processed based on the fixed information, the change of the pattern for the embroidering and dyeing (e.g., configuration and colors) and the operational order (i.e., embroidering and dyeing) is unlikely changed.

A need thus exists for an embroidering and dyeing system which reduces the idle time, prevents the deviation of the relative position of the embroidering pattern and the dyeing pattern, enables the embroidering and dyeing without being affected by the stock or the particular color of the thread, and is flexible for the change of the pattern designs and the operational order.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and additional features and characteristics of the present invention will become more apparent from the following detailed description considered with reference to the accompanying drawing figures in which like reference numerals designate like elements.

FIG. 1 shows an overview of an embroidering and dyeing system according to embodiments of the present invention.

FIG. 2 shows a perspective view of an embroidering machine of the embroidering and dyeing system shown in FIG. 1.

FIG. 3 shows a block view illustrating a control system of the embroidering machine of the embroidering and dyeing system of FIG. 1.

FIG. 4 is a flowchart showing the calculation of embroidering time when inputting pattern data of the embroidering machine shown in FIG. 2.

FIG. 5 is a flowchart showing the calculation of embroidering time at embroidering operation of the embroidering machine shown in FIG. 2.

FIG. 6 shows a perspective view of a dyeing machine of the embroidering and dyeing system shown in FIG. 1.

FIG. 7 shows a block view illustrating a control system of the dyeing device shown in FIG. 6.

FIG. 8 shows a cross-sectional view of the dyeing device in X-direction shown in FIG. 6.

FIG. 9 shows a cross-sectional view of the dyeing device when a thick cloth is positioned of FIG. 6.

FIG. 10 shows a cross-sectional view of a printer after adjusting the height of a table in accordance with the thickness of the cloth shown in FIG. 9.

FIG. 11 shows a cross-sectional view of an ink output portion of the dyeing device of FIG. 6.

FIG. 12 shows a cross-sectional view of the dyeing device shown in FIG. 6 when another cloth is positioned.

FIG. 13 shows a state that a control device and the embroidering machine are positioned on a rack, which accommodates the printer.

FIG. 14 is a plane view showing an optimum arrangement of the embroidering and dyeing system including one printer and plural embroidering machines.

FIG. 15 shows an overview of an embroidering and dyeing system according another embodiment of the present invention.

FIG. 16 shows a cross-sectional view of a frame device configured to stretch and hold a cloth.

FIG. 17 is an explanatory view for a pattern embroidered depending on embroidering data.

FIG. 18 is an explanatory view for an actually embroidered pattern.

FIG. 19 is a view showing a principle for calculating an amount for correcting the deviation of a relative position between the embroidering pattern and the dyeing pattern by measuring the coordinate displacement.

FIG. 20 is an explanatory view showing a pattern embroidered based on the embroidering data.

FIG. 21 is an explanatory view showing a pattern actually embroidered.

FIG. 22 is an overview of a pattern.

FIG. 23 is a view showing contents displayed on the screen during forming the pattern of FIG. 22.

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will be explained with reference to the illustrations of the drawing figures as follows.

As shown in FIG. 1, an embroidering and dyeing system EBS includes a control device 100, an embroidering machine 200 separated from the control device 100 and controlled by the control device 100, and a dyeing device 300 separated from the control device 100 and controlled by the control device 100.

With the construction of the embodiment of the present invention, a personal computer is used as the control device 100. Microcomputer may be used as the control device 100.

As shown in FIG. 1, a CPU 122 serving as a central element of the control device 100 is accommodated in a casing 130 for boarding a display 134 serving as a displaying device. An inputting means 131 including a keyboard 132 and a mouse 133 is connected to the CPU 122. A disc drive 129 for reading in various data from a flexible disc is provided. The disc drive 129 is connected to the CPU 122. The data read in the CPU 122 is memorized in an internal memory.

When a starting switch is ON, the control device 100 assumes an operational state. Simultaneously, an initial picture appears on a screen 137 of the display 134 so that plural embroidering patterns are displayed in order. The patterns are, for example, mainly categorized as follows.

(A) The pattern attained by dyeing with the dyeing device 300 after embroidering on a cloth W serving as a work piece with the embroidering machine 200.

(B) The pattern attained by embroidering on the cloth W serving as the work piece with the embroidering machine 200 after dyeing the cloth W with the dyeing device 300.

(D) The pattern attained by dyeing the cloth W serving as the work piece with the dyeing device 300.

By clicking the desired pattern using the mouse 133, a second picture explained hereafter appears. The contents of the second picture depends on the selected pattern, for example, (A)-(D).

Thus, when one of the patterns are selected, the corresponding pattern data is read from one of the memories, 228, 229, 230, 230A (shown in FIG. 3) so that the embroidering machine 200 and the dyeing device 300 operates to create the selected pattern on the cloth W serving as the work piece.

The embroidering and dyeing system EBS includes the dyeing device 300 in addition to the control device 100 and the embroidering device 200 included in the known embroidering and dyeing system. The embroidering machine 200 and the dyeing device 300 are controlled using software loaded on the control device 100.

As shown in FIG. 13, the space efficiency may be increased by loading the control device 100 and the embroidering device 200 on a top panel of a rack 800 for accommodating the dyeing device 300 to be drawn thereon.

The construction of the embroidering machine 200, the operation of the embroidering machine 200, the construction of the dyeing device 300, the operation of the dyeing device 300, and the total operation of the embroidering and dyeing system EBS will be explained as follows.

The construction of the embroidering-machine 200 will be explained with reference to FIGS. 2-3. The embroidering machine 200 includes a sewing machine 201 and an X-Y table 205 positioned under the sewing machine 201. The X-Y table 205 includes an embroidery frame drive portion operated by an X motor 226A and Y motor 226B (shown in FIG. 3). An embroidery frame device FR is attached to the embroidery frame drive portion. The moving amount and the moving direction of the embroidery frame device FR moved by the embroidery frame drive portion is calculated by the embroidery data.

A needle of the sewing machine 201 is configured to move upward and downward by a top shaft motor 227. Thus, the embroidering machine 200 embroiders the pattern according to the pattern data on the cloth W by selecting the pattern after sewing the cloth W at an embroidery frame F.

The CPU 122 in the control device 100 serves as an embroidering time calculation means for converting the embroidering data into the time, a required time calculation means, and a remaining time calculation means. In other words, the CPU 122 is connected to program memories written with aforementioned calculation programs, a RAM for the operation, memories 228, 229, 230, 230A written with the plural pattern data, a drive means 231 for driving the top shaft motor 227, and a pulse distribution circuit 224 for driving the X-motor 226A and the Y-motor 226B.

By operating one of the inputting means 131 of the keyboards 132 and the mouse 133, one of the memories 228, 229, 230, 230A assumes readable to read the selected pattern data. The pattern data commands the needle piercing point at a plane surface coordinate system relative to the embroider frame device FR. The ratio between needle piercing points of the consecutive two pattern data of the length in the X direction and the length in the Y direction commands the pulse distribution ration of the X-motor 226A and the Y-motor 226B. The length of the hypotenuse of the right triangle determined by the length in the X-direction and the length in the Y-direction determines the pitch length between the consecutive needle piercing points, and the shaft motor 227 varies the rotational speed in accordance with the pitch length. The top shaft 227 is attached with an encoder 227a. The pulse output of the encoder 227a assumes a reference drive signal for driving the X-motor 226A and the Y-motor Y by the feedback to the CPU 122.

In this case, the operator can select the highest rotational speed of the top shaft 227. The highest rotational speed corresponding to the embroidering speed determines the embroidering precision. The highest rotational speed of the top shaft motor 227 adjusts the rotational speed of the top shaft 227 determined in accordance with the pitch length.

The operation of the embroidering machine 200 will be explained referring to FIGS. 4-5 as follows. As shown in FIG. 4, the flowchart shows the calculation of the required time from the start to the end of the embroidering at the input of the pattern data. Before entering the main flow, the operator sets the cloth W at the embroidering device FR. After cloth is placed, at Step S1, the CPU 122 calculates the embroidering time thin corresponding to the pitch length at the selected pitch length. In this case, the value of the total register of the embroidering time is set at zero (=0).

At Step S2, each pitch length is calculated from every two consecutive embroidering data to obtain the embroidering time per stitch. The embroidering time per stitch is obtained based on the rotational speed of the top shaft motor 227 determined from the pitch length. When the embroidering time t per stitch obtained at Step S2 is greater than the embroidering time t_mindetermined by the embroidering speed at the judgment of Step S3, t is added to the total register as is. When the embroidering time t per stitch obtained at Step S2 is equal to or less than the embroidering time t_min, t is determined to be t_min(t=t_min) at Step S4 to forward the transaction to Step S5. At Step S5, the embroidering time t of every two consecutive embroidering data is summed. At Step S6, whether the embroidering data is left is judged.

The routine of Steps S2-S6 is repeated until the operation is completed for the all pattern data. When the judgment of Step S6 shows that the data is not left (YES), the required time T from the start to the end of the embroidering is obtained. The required time T is shown on the screen 137 of the display 134. After displaying the required time T, the embroidering operation starts. With the embroidering machine 200, the remained time of the embroidering time shown in FIG. 5 is displayed by the interrupting transaction even during the embroidering operation. The calculation at FIG. 5 is basically the same with the calculation at FIG. 4, and the embroidering time per open stitch is obtained from the two consecutive embroidering data read out during the embroidering operation to be successively subtracted from the required time T.

In case the embroidering operation starts at a state that the required time T is displayed at Step S7, the embroidering data is successively read out. The CPU 122 calculates the pitch length of needle piercing points by the two consecutive embroidering data on the process of embroidering to obtain an embroidering time t′ of every consecutive embroidering data by the calculation likewise at Step S2. The embroidering time t′ is compared to the embroidering time t′_minat Step S9. In case the embroidering time t′ is greater than the embroidering time t′_min, the transaction is forwarded to Step 11. In case the embroidering time t′ is equal to or less than the embroidering time t′_min, the embroidering time t′ and the embroidering time t′_minis equalized at Step S10 and the transaction is forwarded to Step S11. Step S11 corresponds to Step 5 for calculating the total embroidering time T′ used for the embroidering operation thus far. At Step S12, the total embroidering time T′ is subtracted from the required time T. The remaining embroidering time T″ is displayed at Step S13. After displaying Step S13, the transaction returns to Step S8 when the further pattern data is left at Step S14. A loop from Step S8 to Step S14 is repeated until the operation for the all data is completed at Step S14.

With the construction of the present invention, because the embroidering time per stitch is obtained from the pattern data to calculate the total required time to be displayed before the embroidering operation, the required time from the start to the end of the embroidering is judged. Thus, the precise time management for arranging the embroidering and the other operation can be achieved, which increases the production performance and assumes easier to estimate the productivity per time.

In addition, because the embroidering time t′ of the every consecutive embroidering data during the embroidering process is obtained and summed to be subtracted from the required time T, the remaining time T″ until the end of the embroidering can be displayed. Further, because the embroidering time t′ for the every consecutive embroidering data during the embroidering process is obtained to be summed, the passage of time in accordance with the progress of the embroidering operation can be displayed while displaying the required time at the screen 137.

The construction of the dyeing device 300 will be explained referring to FIGS. 6-7. As shown in FIGS. 6-7, the dyeing device 300 includes an independent MPU (central processing device) 305. The dyeing information is read into a. RAM 306 from the CPU 122 of the control device 100 via an interface 304 and the WPU 305, either successively or collectively.

As shown in FIG. 6, a frame 307 of the dyeing device 300 includes the converted U shape and a table 308 is positioned for enabling upward and downward movement at a central portion. An operational panel 329 for operating the input is provided at the top surface of the frame 307 relative to the MPU 305 independent from the dyeing information sent from the CPU 122. A warm air current generator 335 including a heater 335a and a fan 335b for providing the warm current of the air to the top surface of the cloth W is provided at an end portion of the frame 307. Grooves 307a are provided at sides of the frame 307. End portions of Y-direction movement bar 309 moving in the Y-direction along the groove 307a is provided at the groove 307a. A groove 309a is provided at side surface of the Y-direction bar 309. An X-direction movement arm 310 provided with a printing portion 311 at a tip end thereof is provided at the groove 309a to be movable in the X-direction. When the actuation is commanded from the MPU 305 to an XY-motor drive 330. (shown in FIG. 7), the X-motor 310b and the Y-motor 309b rotate in accordance with the moving distance so that the X-direction movement arm 310 and the Y-direction bar 309 moves to move the printing portion 311 two-dimensionally.

A holding frame device FR (shown in FIGS. 8-10) for holding the cloth W includes a circular frame body FRa (shown in FIG. 8-10), an engagement frame device FRb engaging at an internal periphery of the frame body FRa for holding the cloth W between the frame body FRa, and an attaching portion FRc secured to the end portions of the frame body FRa to be extended towards the frame 307. A pair of stepped portion 307c is formed at the top surface of the frame 307. The holding frame device FR is fixed to the stepped portion 307c via screws. As shown in FIG. 8, a sensor 314 is provided at a portion immediately bottom of one of the attaching portions FRc. The sensor 314 is connected to the MPU 305 and detects the distance between the frame 307 and the attaching potion FRc for transmitting to the MPU 305.

A pinion 315 is formed at an internal surface of the frame 307. A pair of rack 316 geared with the pinion 315 is pivoted at the side surfaces of the table 308. A belt 317 is wound around the racks 316. A stepping motor 318 pivoted with a rotational shaft 319 is positioned in the table 308. The belt 317 is geared with the rotational shaft 319. When the actuation is commanded to the stepping motor 318 from the MPU 305 via the motor drive 320, the belt 317 and the rack 316 rotate. In this case, because the belt 317 is twisted and wound around the rack, the racks 316 rotates in the opposite direction by the rotation of the stepping motor 318. Thus, the table 308 moves upward when the stepping motor 318 rotates in the clockwise direction of FIG. 9. The table 308 moves downward when the stepping motor 318 rotates in the counterclockwise direction.

The construction of the printing portion 311 provided at the tip end of the X-direction movement arm 310 will be explained as follows. As shown in FIG. 11, the printing portion 311 includes three ink heads including blue, red, and yellow. The ink head 321 is fixed to an ink head holding member 322. When the command for dyeing is transmitted from the MPU 305 to a head drive 324 (shown in FIG. 7), the ink head 321 having the specified color moves downward from the ink head holding member 322 to dye on the cloth W. A sensor 328 is provided on the ink head holding member 322 corresponding to each ink head 321. The sensor 328 detects the distance from the cloth W to send to the MPU 305. The both ends of the ink head holding member 322 are positioned through a pair of guide bar 323 provided in the X-direction movement arm 310. Pulleys 325a, 325b adjacent to the guide bar 323 are arranged at the top and bottom at the internal surface of the X-direction movement arm 310. An ink head motor 327 is provided at the pulley 325a. A belt 326 is wound around the pulleys 325a, 325b. An end portion of the ink head holding member 322 is attached at the belt 326. Thus, by the rotation of the pulleys 325a, 325b by the operation of the ink head motor 327, the belt 326 rotates to actuate the ink head holding member 322 upward and downward along the guide bar 323.

The dyeing device 300 includes an independent MPU 305 for using the dyeing device 300 independent from the control device 100. In other words, by connecting a scanner to the interface 304 and by memorizing the figure read from the scanner in a RAM 306 as the digital information, the figure can be dyed on another cloth.

The operation of the dyeing device 300 will be explained referring to FIGS. 10-12 as follows. First, the cloth W is set at the holding frame device FR at a state that a screw 313 for fixing the holding frame device FR to the frame 307 is loosened. In this case, the table 308 is positioned at the highest level. By setting the cloth W at the holding frame device FR, the attaching portion FRc of the holding frame device FR moved upward by the thickness Δd of the cloth W (shown in FIG. 10). By commanding the correction of the height of the table 308 by the operation panel 329, the sensor 314 measures the distance between the frame 307 and the attaching portion 312c to send to the MPU 305. Thereafter, the MPU 305 sends the command to the motor drive 320 for rotating the stepping motor 318 to move the table downward by Δd. Thus, the distance between the frame 307 and the attaching portion FRc is adjusted to be d and the distance between the ink head 321 and the cloth W is adjusted simultaneously (shown in FIG. 11). When the command to start the dyeing is sent, the MPU 305 send the command to scan the X-direction movement arm 310 and the Y-direction movement bar 309 per one line or per plural lines based on the dyeing information inputted in the RAM 306 and dyes the cloth W by moving the ink head 321 with three colors following the dyeing information.

As foregoing, although the cloth W is dyed while maintaining a predetermined distance between the cloth W and the ink head 321, when a different cloth 332 such as the appliqué is partially overlapped on the cloth W as shown in, FIG. 12, the height between the ink head 321 and the different cloth 332 is adjusted in the following manner. The sensor 328 provided adjacent to the ink head 321 always detects the distance between the tip end of the ink head 321 and the cloth W and between the tip end of the ink head 321 and the different cloth 322 to send to the information to the MPU 305. When the distance exceeds a predetermined length, the MPU 305 commands the motor drive 320 for actuating the ink head motor 327 to move the ink head holding member 322 upward. When it is sensed that the overlapping with another cloth on the cloth W is cleared, the ink head holding portion 322 is moved downward.

When the warm current of the air is commanded to be sent at the operation panel 329 at the dyeing, the MPU 305 commands the energization to the heater 335a and the fan 335b to send the warm current of the air of the cloth W from the warm air current generator 335, which dries the ink fast.

The operation of the embroidering and dyeing system will be explained as follows. When a starting switch is ON, the control device 100 assumes the operation state. Simultaneously, an initial picture appears at the screen 137 of the display 134 so that the plural patterns are arranged to be displayed. The patterns mainly include, for example, the following categories.

(A) The pattern obtained by dyeing by the dyeing device 300 after embroidering on the cloth W by the embroidering machine 200;

(B) The pattern obtained by embroidering by the embroidering machine. 200 after dyeing the cloth W by the dyeing device 300;

(D) The pattern obtained by dyeing the cloth W by the dyeing device 300.

By clicking the desired pattern with the mouse 133, the second picture including the selected pattern and the command in accordance with the selected pattern appears on the screen in accordance with the selected pattern. The operation of the embroidering and dyeing system will be explained depending on the selected patterns.

When the pattern (A), the pattern obtained by dyeing with the dyeing device 300 after embroidering on the cloth W by the embroidering machine 200 is selected, the screen 137 displays the pattern and the command saying “input the frame number, and set the frame set with the cloth at the embroidering machine” or the like. Following the command, by setting the frame device FR set with the cloth W to the embroidering machine 200 after inputting the number showing the size of the frame device FR set with the cloth W to operate the embroidering machine 200, the frame device FR moves to the embroidering starting point according to the size thereof to apply the predetermined embroider on the cloth W. During the embroidering operation, the time until completing the operation is displayed at the screen 137. When the embroidering operation is completed, the buzzer sounds and the commands saying “set the cloth at the dyeing device without removing from the frame”, or the like, is displayed. Following the command by setting the frame device FR set with the cloth W at the dyeing device 300 to operate the dyeing device 300, the frame device FR moves to the dyeing starting point according to the size thereof (i.e., the size is acknowledged by the control device 100 when inputted at screen 137), the specified portion of the embroidered cloth W is dyed. When the ink is completely dried by the completion of the dyeing operation, the buzzer sounds and the command saying “remove the frame”, or the like is displayed. Accordingly, the cloth W dyed after the embroidering can be obtained. By switching the usage mode of the dyeing device 300 during the embroidering operation, separate cloth can be dyed independently.

In case the pattern (B), the pattern obtained by embroidering by the embroidering machine 200 after dyeing the cloth W by the dyeing device 300, is selected, the command saying “input the frame number, and set the frame set with the cloth to the dyeing device” or the like, is displayed on the screen 137. By setting the frame device FR set with the cloth W to the dyeing device 300 and operating the dyeing device 300 after inputting the number indicating the size of the frame device FR set with the cloth W at the screen 137, the frame device FR is moved to an initial position for the dyeing in accordance with the size of the frame device FR so that the predetermined dye is provided at the cloth W. When the dyeing operation is completed and the ink is completely dried, the buzzer sounds and the command saying “set the frame to the embroidering device without removing the cloth from the frame” or the like, is displayed. By setting the frame device FR set with the dyed cloth W to the embroidering machine 200 and operating the embroidering machine 200, the frame device FR is moved to the initial position for the embroidering in accordance with the size of the frame device FR (i.e., the size of the frame device FR is known by the control device 100 when inputted at the screen 137) so that the predetermined embroider is provided on the cloth W. During the embroidering operation, the time until the completion of the operation is displayed on the screen 137. When the embroidering operation is completed, the buzzer sounds and the command saying “remove the frame” or the like is displayed. Thus, the cloth W provided with the embroider after dyeing can be obtained. By switching the usage mode of the dyeing device 300 during the embroidering operation, another cloth can be dyed independently from the embroidering operation.

In case the pattern (C), the pattern obtained by embroidering on the cloth W by the embroidering machine 200, is selected, the selected pattern and the command saying “input the frame number, and set the frame set with the cloth W to the embroidering machine” or the like is displayed. By setting the frame device FR set with the cloth W to the embroidering machine 200 and operating the embroidering machine 200 after inputting the number showing the size of the frame device FR set with the cloth W at the screen 137 following the direction, the frame device FR is moved to the initial position for the embroidering in accordance with the size of the frame device FR so that the predetermined embroider is provided on the cloth W. During the embroidering operation, the time until the completion of the operation is displayed at the screen 137. When the embroidering operation completes, the buzzer sounds and the command saying “remove the frame” or the like is displayed; Thus, the cloth W provided with the embroider can be obtained. By switching the usage mode of the dyeing device 300 during the embroidering operation, the cloth can be dyed on another cloth independently from the embroidering operation.

In case the pattern (D), the pattern obtained by dyeing the cloth W by the dyeing device 300, is selected, the selected pattern and the command saying “input the frame number, and set the frame set with the cloth to the dyeing device” is displayed on the screen 137. By setting the frame device FR set with the cloth W to the dyeing device 300 and operating the dyeing device 300 after inputting the number for indicating the size of the frame device FR set with the cloth W at the screen 137, the predetermined dye is provided on the cloth W. When the dyeing operation is completed and the ink is completely dried, the buzzer sounds and the command saying “remove the frame,” or the like is displayed. Thus, the cloth W provided with the dyeing can be obtained. The same pattern can be obtained even if the dyeing device 300 is operated independently from the embroidering machine 200.

Although the embroidering and dyeing system EBS of the foregoing embodiment performs the embroidering and/or dyeing consecutively or simultaneously under the common control by the control device 100 for one embroidering machine 200 and one dyeing device 300, the construction of the present invention is not limited to the foregoing construction.

According to a second embodiment of the present invention, the common control device 100 controls plural embroidering machines 200 and one dyeing device 300. With this construction, the embroidering and dyeing operation can be performed more efficiently. In case the required time for the embroidering operation is less than a half of the required time for the dyeing operation including drying the ink, for example, the idle time of the embroidering machine 200 and the dyeing device 300 can be reduced to the minimum by operating the embroidering operation twice during the dyeing operation.

According to a third embodiment of the present invention, the common control device 100 controls one embroidering machine 200 and the plural dyeing devices 300. This construction provides more efficient embroidering and dyeing operation. In case the required time for the embroidering operation is greater than twice of the required time for the dyeing operation including drying the ink, the idle time of the embroidering machine 200 and the dyeing device 300 can be reduced to the minimum by operating the dyeing operation twice during the embroidering operation. As shown in FIG. 14, by providing the plural numbers of embroidering machines 200A-200D, for example, with the equal intervals from each other surrounding the dyeing device 300 positioned at the rotation table 900, the operation can be efficient. In other words, by determining the embroidering time at the embroidering machines 200A-200D as TE and determining the dyeing time at the dyeing device 300 as TC and TE is determined to be equal to four times of TC (TE=4TC), for example, by delaying the starting time of the embroidering machines by (¼) T, the embroidering operation at the embroidering machine is completed and the cloth is dyed by the dyeing device 300 without generating the idle time of the dyeing device 300 simultaneous with the completion of the embroidering operation at each embroidering machine, which improves the efficiency of the total operation. When the embroidering operation is completed at the particular embroidering machine, the setting of the dyeing device 300 to the frame device FR assumes easy by rotating the rotation table 900.

According to a fourth embodiment of the present invention, different frame devices for holding the cloth W may be used for embroidering by the embroidering machine 200 and for dyeing by the dyeing device 300. In this case the information of the size of the frame device may be inputted from the control device 100 to the embroidering machine 200 and the dyeing device 300 individually in advance (i.e., the command at the screen 137 may be different from the first embodiment). Thus, the cloth (i.e., work piece) set at the frame device can be precisely moved to the predetermined initial position of the embroidering and the initial position of the dyeing by actuating the frame device depending on the size of the frame device.

According to the embodiment of the present invention, by providing the control software for controlling the embroidering machine and the dyeing device adding the dyeing device to the embroidering machine, the embroidering and the dyeing to the work piece can be performed simultaneously or consecutively. In this case, even if there is the relatively large differences between the embroidering time and the dyeing time, the idle time for either one of the embroidering machine or the dyeing device can be reduced by increasing or decreasing the number for the embroidering machine or the dyeing device properly.

According to the embodiment of the present invention, because the size of the frame to be set is informed to the both embroidering machine and the dyeing device by the control software, the movement of the frame to the starting point of the embroidering at the embroidering machine and the starting point of the dyeing at the dyeing device can be performed precisely with the common frame and the different frames, which prevents the embroidering and the dyeing at the undesired position.

A fifth embodiment of the present invention will be explained with reference to FIGS. 15-21 as follows.

As shown in FIGS. 15-16, an embroidering and dyeing system EBS includes a control device 510, an embroidering machine 520 separated from the control device 510 and controlled by the control device 510, and a dyeing device 530 separated from the control device 510 and controlled by the control device 510. With the embroidering and dyeing system EBS, the pattern is embroidered on a cloth W stretched and held at a frame device 540 by the embroidering machine 520 before or after dyeing the pattern by the dyeing device 530.

In case the cloth W is dyed after the embroidering, the relative relationship of the dyeing pattern relative to the embroidering pattern is adjusted considering the shrinkage of the cloth W due to the embroidering. As shown in FIG. 17, in case a zigzag pattern ZA having an amplitude amount LA is embroidered within a rectangular RA shown with a dotted line, the embroider actually assumes to have a zigzag pattern ZB having an amplitude amount LB by the shrinkage of the cloth as shown in FIG. 18. In other words, the pattern shrinks by LA-LB in the width direction after the embroidering operation. Thus, with the embroidering and dyeing system of the embodiment, the size of the dyeing pattern is adjusted considering the shrinkage direction and the shrinkage amount (i.e., the correcting direction and the correcting amount) to dye a rectangular RB within the range of the zigzag pattern ZB.

The relative position between the dyeing pattern and the embroidering pattern, explained as foregoing, is corrected by determining the correction direction and the correction amount by the trial embroidering. The correction of the relative position between the dyeing pattern and the embroidering pattern may be determined by a try and error method. With this method, first, the embroidering pattern ZA as shown in FIG. 17 is formed, and volatile ink is jetted on the embroidered cloth to dye the pre-corrected pattern. Comparing the dyed pattern formed with the volatile ink and the embroidered pattern, the deviation is measured by eyes to feedback the result to the correction of the size of the dyed pattern. Because the pattern dyed with the volatile ink disappears after the passage of predetermined time, the operation can be repeated and the relative position between the dyed pattern and the embroidered pattern can be corrected by dyeing the pattern within the corrected dyeing range, using the normal ink when the pattern for dyeing and the pattern for the embroidering match each other.

With the embroidering and dyeing system EBS, the pattern is dyed by the dyeing device 530 after embroidering the pattern on the cloth W stretched and held at the frame device 540 by the embroidering machine 520. In this case, the position may be deviated when the frame device 540 is set to the frame device 540. The correction of the relative position between the pattern for dyeing and the pattern for embroidering considering the foregoing condition is performed explained as follows.

First, the frame device 540 stretched and held with the cloth W is set at the embroidering machine 520.

Second, the control device 510 memorizes the arbitrary coordinates WA (XA, YA) and WB (XB, YB) positioned at a linear line (shown in FIG. 19). The point WA may be marked by, moving a sewing machine head to a proper position, stopping the sewing machine head, and piercing the needle on the cloth. In this case the coordinate (XA, YA) of the point WA is acknowledged by the control device. Further, the point WB is determined by moving the sewing machine head in the X direction, stopping thereof at proper position, and the needle is pieced. At this timing, the coordinate (XB, YB) of the point WB is acknowledged by the control device.

Third, the frame device 540 stretched and holding the cloth W is set at the dyeing device 530.

Fourth, an ink head of the dyeing device 530 is moved so that the jet point faces the marked point WA. In this case, the coordinate recognized by the control device is determined to be (XC, YC) as shown in FIG. 19. Further, the ink head is moved so that the jet point faces the marked point WB. In this case, the coordinate recognized by the control device is determined to be XD, YD).

Thus, the deviation (i.e., the inclination θ and the displacement amount DP) from the coordinates (XA, YA), (XB, YB), (XC, YC), and (XD, YD) relative to the origin of the frame device 540 set to the dyeing device 530 is calculated. By correcting the dyeing range of the pattern for dyeing in accordance with the deviation, the relative position between the dyed pattern and the embroidered pattern can be appropriately adjusted.

In case the foregoing method is adopted, by marking two other points (XP, YP) and (XQ, YQ) and calculating the shrinkage direction and the shrinkage amount using the points (XP, YP), (XQ, YQ) and (XA, YA), (XB, YB) to reflect on the correction, the correction can be further precise.

The relative position between the pattern for dyeing and the pattern for the embroidering may be corrected in the following manner.

First, an embroidered pattern EMB as shown in FIG. 7 is provided on the cloth W by setting the frame device 540 stretching and holding the cloth W.

Second, the embroidering frame 240 stretched and held with the cloth W is set at the dyeing device 530.

Third, arbitrary coordinates EMX (XA, YA) and EMY (XB, YB) are memorized by clicking with mouse at a pattern EMA for embroidering displayed on a display 250.

Fourth, the ink head of the dyeing device 530 is moved so that the jet point aiming points FMX, FMY corresponding to the EMX, EMY on the actual embroidered pattern EMB. The coordinates are determined as FMX (XC, YC) and FMY (D, YD).

Thus, because the deviation (inclination and the displacement amount) from the coordinates (XA, YA), (XB, YB), (XC, YC), and (XD, YD) relative to the origin of the frame device 540 set at the dyeing device 530 is calculated, the relative position between the pattern for dyeing and the pattern for embroidering can be appropriately adjusted by correcting the dyeing range of the pattern for dyeing in accordance with the deviation.

With the foregoing methods, it is not necessary to use the frame device 540 for setting the cloth W to the dyeing device 530.

According to the embodiment of the present invention, the relative position between the pattern for dyeing and the pattern for embroidering is corrected with the embroidering and dyeing system for embroidering the pattern on the cloth by the embroidering machine before or after the dyeing pattern on the cloth by the dyeing device, the deviation of the relative position between the pattern for embroidering and the pattern for dyeing caused by the deviation of the position of the frame device for stretched and holding the cloth or by the shrinkage of the cloth can be eradicated.

A sixth embodiment of the present invention will be explained as follows.

The construction of the embroidering and dyeing system according to the sixth embodiment is basically the same with the construction of the first embodiment. The construction of the embroidering machine 200 will be further explained referring to FIG. 2. The embroidering machine 200 includes an embroidering frame actuation portion for actuating the embroidering frame device FR by the X-motor 226A and the Y motor 226B two-dimensionally on the plane surface (i.e., X direction and Y direction), a sewing mechanism 201 for actuating embroidering needles 281-289 positioned right above of a needle piercing hole 260, and a needle selecting device 216. As described in Japanese published examined applications Nos. S53-43336 and S55-8626, the needle selecting device 216 selectively set one of needles 581-589 at right above of the needle piercing hole 260, thus the embroidering is performed using the thread guided at the needle positioned right above of the needle piercing hole 260.

The sewing machine arm is attached with a bobbin holder 255. The bobbin holder 255 can accommodate ten bobbins. Nine bobbins are guided with the thread at needles 581-589 via a tension 261 and a thread guiding board 262 and a hole provided at a thread take-up lever.

The pattern data is specified with a particular name (i.e., file name). The information for the embroidering of the particular name of each pattern includes the small number of management data and the large number of stitch data. The management data includes the data for a predetermined thread color Ci and selecting order of the thread color. The stitch data includes two kinds of the information, that is, the first kind is the control data including thread substitution command data and end command data (i.e., embroidering completion command data). The second kind is the frame actuation amount data showing a predetermined actuation amount (X-axis moving amount and Y-axis moving amount) from the last embroidering frame position (i.e., the frame center is positioned at the right above of the needle piercing hole 260 at the start). With the stitch data, the frame actuation amount data is arranged in order by one stitching unit when the thread substitution is not performed and the embroidering is not completed. The thread substitution command data is provided at the timing of the thread substitution. The timing for ending the embroidering, that is the end of the stitch data, is the end command data. The thread color adopts the RGB code.

The memory device of the control device 100 (e.g., personal computer) memorizes the thread color supplied to the needles 281-289 and the needle number N1-N9 provided to the nine needles 281-289 of the embroiling machine 200 as the pairs [Nj, Cj] (j=1-9) via the input device such as keyboard and the mouse.

The desired pattern with the plural colors is embroidered with the embroidering machine. 200 by operating the embroidering and dyeing system.

First, the colored image of the pattern with plural desired colors for embroidering is displayed on the display. The pattern displayed on the screen is shown with a line drawing with colors corresponding to the threads.

Second, in case replacing the currently displayed color with different color of the thread, the operator selects the favorable color from the color data table shown on the screen when clinking the line drawing. Thereafter, the content of the predetermined thread color Ci of the management data is corrected and the needle number Ni is added corresponding to the selected color. In case the selected colored thread is provided at none of the needles, the closest color among the provided is selected.

Third, the embroidering data is sent from the control device 100 to the CPU of the embroidering machine 200.

Fourth, the embroidering machine 200 receiving the embroidering data is actuated to produce the embroider pattern with plural colors defined by the embroidering data.

The CPU 122 in the control device 100 serves as an embroidering time calculation means for converting the embroidering data into the time, a required time calculation means, and a remaining time calculation means. In other words, the CPU 122 is connected to program memories written with aforementioned calculation programs, a RAM for the operation, memories 228, 229; 230, 230A written with the plural pattern data, a drive means 231 for driving the top shaft motor 227, and a pulse distribution circuit 224 for driving the X-motor 226A and the Y-motor 226B.

The operation of the embroidering machine 200 will be explained referring to FIGS. 4-5 as follows. As shown in FIG. 4, the flowchart shows the calculation of the required time from the start to the end of the embroidering at the input of the pattern data. Before entering the main flow, the operator sets the cloth W at the embroidering device FR. After cloth is placed, at Step S1, the CPU 122 calculates the embroidering time t_mincorresponding to the pitch length at the selected pitch length. In this case, the value of the total register of the embroidering time is set at zero (=0).

The construction of the dyeing device 300 will be explained referring to FIGS. 6-7. As shown in FIGS. 6-7, the dyeing device 300 includes an independent MPU (central processing device) 305. The dyeing information is read into a RAM 306 from the CPU 122 of the control device 100 via an interface 304 and the MPU 305, either successively or collectively.

As shown in FIG. 6, a frame 307 of the dyeing device 300 includes the converted U shape and a table 308 is positioned for enabling upward and downward movement at a central portion. An operational panel 329 for operating the input is provided at the top surface of the frame 307 relative to the MPU 305 independent from the dyeing information sent from the CPU 122. A warm air current generator 335 including a heater 335a and a fan 335b for providing the warm current of the air to the top surface of the cloth W is provided at an end portion of the frame 307. Grooves 307a are provided at sides of the frame 307. End portions of Y-direction movement bar 309 moving in the Y-direction along the groove 307a is provided at the groove 307a. A groove 309a is provided at side surface of the Y-direction bar 309. An X-direction movement arm 310 provided with a printing portion 311 at a tip end thereof is provided at the groove 309a to be movable in the X-direction. When the actuation is commanded from the MPU 305 to an XY-motor drive 330 (shown in FIG. 7), the X-motor 310b and the Y-motor 309b rotate in accordance with the moving distance so that the X-direction movement arm 310 and the Y-direction bar 309 moves to move the printing portion 311 two-dimensionally.

As foregoing, although the cloth W is dyed while maintaining a predetermined distance between the cloth W and the ink head 321, when a different cloth 332 such as the applique is partially overlapped on the cloth W as shown in FIG. 12, the height between the ink head 321 and the different cloth 332 is adjusted in the following manner. The sensor 328 provided adjacent to the ink head 321 always detects the distance between the tip end of the ink head 321 and the cloth W and between the tip end of the ink head 321 and the different cloth 322 to send to the information to the MPU 305. When the distance exceeds a predetermined length, the MPU 305 commands the motor drive 320 for actuating the ink head motor 327 to move the ink head holding member 322 upward. When it is sensed that the overlapping with another cloth on the cloth W is cleared, the ink head holding portion 322 is moved downward.

The operation of the embroidering and dyeing system EBS will be explained as follows. When a starting switch is ON, the control device 100 assumes the operation state.

Simultaneously, an initial picture appears at the screen 137 of the display 134 so that the plural patterns are arranged to be displayed. The patterns mainly include, for example, the following categories.

(A) The pattern obtained by dyeing with the dyeing device 300 after embroidering on the cloth W by the embroidering machine 200;

(B) The pattern obtained by embroidering by the embroidering machine 200 after dyeing the cloth W by the dyeing device 300;

(D) The pattern obtained by dyeing the cloth W by the dyeing device 300.

When the pattern (A), the pattern obtained by dyeing with the dyeing device 300 after embroidering on the cloth W by the embroidering machine 200 is selected, the screen 137 displays the image of the pattern with color. The pattern shown on the screen is illustrated with the line drawing with the color corresponding to the thread. In case the color displayed on the screen is changed to another, the operator selects the favorable color from the color data table displayed on the screen when clicking the line drawing. Accordingly, the content of the predetermined thread color Ci of the management data is corrected and the needle number Ni is added corresponding to the selected color. In case the selected color is provided at none of the needles, the pattern embroidered with the unselected color is judged to be produced by dyeing, and thus the needle number provided with the white colored thread is added to automatically correct the data for dyeing.

Thereafter, the command saying “input the frame number, and set the frame set with the cloth at the embroidering machine” or the like is displayed on the screen. Following the command, by setting the frame device FR set with the cloth W to the embroidering machine 200 after inputting the number showing the size of the frame device FR set with the cloth W to operate the embroidering machine 200, the frame device FR moves to the embroidering start point according to the size thereof to apply the predetermined embroider on the cloth W. During the embroidering operation, the time until completing the operation is displayed at the screen 137. When the embroidering operation is completed, the buzzer sounds and the commands saying “set the cloth at the dyeing device without removing from the frame”, or the like, is displayed. Following the command by setting the frame device FR set with the cloth W at the dyeing device 300 to operate the dyeing device 300, the frame device moves to the dyeing starting point according to the size thereof (i.e., the size is acknowledged by the control device 100 when inputted at the screen 137), the specified portion of the embroidered cloth W is dyed. When the ink is completely dried by the completion of the dyeing operation, the buzzer sounds and the command saying “remove the frame”, or the like is displayed. Accordingly, the cloth W dyed after the embroidering can be obtained. By switching the usage mode of the dyeing device 300 during the embroidering operation, another cloth can be dyed independently.

In case the pattern (B), the pattern obtained by embroidering by the embroidering machine 200 after dyeing the cloth W by the dyeing device 300, is selected, the image of the pattern is displayed on the screen 137. The pattern on the screen is shown with the line drawing with the color corresponding to the thread color. In case the color of the thread is changed from the color displayed on the screen, the operator selects the favorable color from the color data table displayed on the screen when clicking the line drawing. Accordingly, the content of the predetermined thread color Ci of the management data is corrected and the needle number Ni is added in accordance with the selected data. In case the selected color is supplied to the none of the needles, it is judged that the pattern embroidered with the unselected color is produced by dyeing, and thus the needle number provided with the white colored thread is added to automatically correct the date for dyeing.

Thereafter, the command saying “input the frame number, and set the frame set with the cloth to the dyeing device” or the like, is displayed on the screen 137. By setting the frame device FR set with the cloth W to the dyeing device 300 and operating the dyeing device 300 after inputting the number indicating the size of the frame device FR set with the cloth W at the screen 137, the frame device FR is moved to an initial position for the dyeing in accordance with the size of the frame device FR so that the predetermined dye is provided at the cloth W. When the dyeing operation is completed and the ink is completely dried, the buzzer sounds and the command saying “set the frame to the embroidering device without removing the cloth from the frame” or the like, is displayed. By setting the frame device FR set with the dyed cloth W to the embroidering machine 200 and operating the embroidering machine 200, the frame device FR is moved to the initial position for the embroidering in accordance with the size of the frame device FR (i.e., the size of the frame device FR is acknowledged by the control device 100 when inputted at the screen 137) so that the predetermined embroider is provided on the cloth W. During the embroidering operation, the time until the completion of the operation is displayed on the screen 137. When the embroidering operation is completed, the buzzer sounds and the command saying “remove the frame” or the like is displayed. Thus, the cloth W provided with the embroider after dyeing can be obtained. By switching the usage mode of the dyeing device 300 during the embroidering operation, another cloth can be dyed independently from the embroidering operation.

In case the pattern (C), the pattern obtained by embroidering on the cloth W by the embroidering machine 200, is selected, the selected pattern and the command saying “input the frame number, and set the frame set with the cloth W to the embroidering machine” or the like is displayed. By setting the frame device FR set with the cloth W to the embroidering machine 200 and operating the embroidering machine 200 after inputting the number showing the size of the frame device FR set with the cloth W at the screen 137 following the direction, the frame device FR is moved to the initial position for the embroidering in accordance with the size of the frame device FR so that the predetermined embroider is provided on the cloth W. During the embroidering operation, the time until the completion of the operation is displayed at the screen 137. When the embroidering operation completes, the buzzer sounds and the command saying “remove the frame” or the like is displayed. Thus, the cloth W provided with the embroidery can be obtained. By switching the usage mode of the dyeing device 300 during the embroidering operation, another cloth can be dyed independently from the embroidering operation.

In case the pattern (D), the pattern obtained by dyeing the cloth W by the dyeing device, 300, is selected, the selected pattern and the command saying “input the frame number, and set the frame set with the cloth to the dyeing device” is displayed on the screen 137. By setting the frame device FR set with the cloth W to the dyeing device 300 and operating the dyeing device 300 after inputting the number for indicating the size of the frame device FR set with the cloth W at the screen 137, the predetermined dye is provided on the cloth W. When the dyeing operation is completed and the ink is completely dried, the buzzer sounds and the command saying “remove the frame” can be displayed. Thus, the cloth W provided with the dyeing can be obtained. The same pattern can be obtained even if the dyeing device 300 is operated independently from the embroidering machine 200.

The content displayed on the screen will be explained referring to FIGS. 13-14 as follows. The message command is displayed on the display 134 of the screen 137 to provide the appropriate command to the operator. In addition, the objective pattern, the operational process for producing the pattern, and the content of the ongoing operation is shown on the screen 137.

For example, the pattern as shown in FIG. 22 may be produced on the cloth by the embroidering and dyeing system. The pattern includes a circle configuration, an A configuration, and a black star configuration. The circle configuration is produced by dyeing with gold color after embroidering. The A configuration is produced by embroidering and the back star configuration is produced by dyeing. For example, in case the embroidering machine 200 is operated before the operation of the dyeing machine 300, the pattern shown in FIG. 22 is produced with the following four steps.

First, embroidering produces the circle configuration.

Second, embroidering produced the A configuration.

Third, the circle configuration produced by the embroidering is dyed.

And, fourth, the black star configuration is dyed.

The control program included in the control device 100 for controlling the embroidering and dyeing system displays the information shown in FIG. 23 on the screen 137 during the operation of the embroidering and dyeing system 100, which provides the sufficient information to the operator for the efficient operation of the embroidering and dyeing. For example, as shown in FIG. 23, the objective pattern is shown at the top portion, the variations of the operation is displayed at the middle portion, and the unit pattern formed by the variation of the operation shown at the middle portion is displayed. One of the frames at the middle portion blinks during the operation.

With the embroidering and dyeing system EBS, the control device 100 assumes the operational state when the starting switch is turned on. Simultaneous with turning on the starting switch, the initial picture appears at the screen 137 of the display 134, where the plural patterns for embroidering are displayed. The patterns are mainly categorized, for example, as follows.

(A) The pattern attained by dyeing with the dyeing device 300 after embroidering on a cloth W serving as a work piece with the embroidering machine 200.

(B) The pattern attained by embroidering on the cloth W serving as the work piece with the embroidering machine 200 after dyeing the cloth W with the dyeing device 300.

(D) The pattern attained by dyeing the cloth W serving as the work piece with the dyeing device 300.

By clicking the desired pattern using the mouse 133, a second picture explained hereafter appears. The contents of the second picture depends on the selected pattern, for example, (A)-(D). When one of the patterns is selected, the corresponding management data, the embroidering data, and the dyeing data are read in from the memories 228, 229, 230, 230A. In case the pattern is attained only by embroidering on the cloth W serving as the work piece with the embroidering machine 200 (i.e., the pattern (C)), the data for dyeing is not read in. In case the pattern is attained only by dyeing the cloth W serving as the work piece with the dyeing device 300 (i.e., the pattern (D)), the data for embroidering is not read in.

The management data includes the thread color and the process order (i.e., the operational order of the embroidering machine 200 and the dyeing device 300) or the like. The embroidering data includes X-Y coordinate of a series of the needle piercing point. The data for dyeing includes a series of X-Y coordinates (i.e., bitmap information) of the points to be jetted with the ink. Thus, the objective unit pattern shown at the bottom on the screen 137 of the display 134 shown in FIG. 23 can be corrected on the screen. The origin of the X-Y coordinate can be changed on the screen.

According to the embodiment of the present invention, the pattern to be embroidered is produced by dyeing in case the thread with desired color is run out, which prevents the intermission of the operation and increases the productivity.

According to the embodiment of the present invention, the embroidering and dyeing device includes the embroidering machine for producing the pattern for embroidering based on the data for embroidering, the dyeing device for producing the pattern for dyeing based on the data for dyeing, and the control device for changing the data for embroidering and the data for dyeing and for controlling the embroidering machine and the dyeing device based on the management data, which enables to produce the favorable patterns for embroidering and dyeing.

Number	Date	Country	Kind
2003-153037	May 2003	JP	national
2003-198006	Jul 2003	JP	national
2003-199966	Jul 2003	JP	national
2003-200567	Jul 2003	JP	national
2003-200568	Jul 2003	JP	national

Embroidering and dyeing system

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CPC

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